Collapsible container that expands when water is added

ABSTRACT

A semi-collapsible container has a hollow body with support and collapsible portions, and can be maintained in a collapsed or an expanded condition. The container is useful for storing liquid, and is especially adapted in its collapsed condition for storing relatively small volumes of concentrated liquid, powders or the like, and in its expanded condition for containing larger volumes of liquid. Via a dispenser in the container, a closure assembly is coupled to the container for securing the contents thereof from leakage.

PRIORITY CLAIM

This application is a divisional application of U.S. patent applicationSer. No. 11/217,088, filed Aug. 31, 2005, titled “Semi-CollapsibleContainer”, which claims priority to U.S. Provisional Patent Application60/606,085, filed Aug. 31, 2004, both of which are incorporated hereinby reference in their entirety.

TECHNICAL FIELD

The invention is generally applicable to semi-collapsible containers.More specifically, the invention is applicable to semi-collapsiblecontainers that expand from a relatively minimum internal volume to alarger internal volume to accommodate the addition of liquid orliquid-based solutions. The containers are particularly useful forstorage of liquid concentrates, powders and the like in the collapsedcondition, and upon addition of a diluting liquid, for the containmentof the diluted contents in the expanded condition.

BACKGROUND OF INVENTION

Many consumer and industrial products are composed of active ingredientsdissolved in solvents, such as water. These type of products havetraditionally been sold preformulated and packaged by the manufacturer.This is to say that the manufacturer dissolves the active ingredients ina solvent, packages the resulting solution in a container, and marketsthe product to its consumer or industrial clients. This method providesfor a fully constituted end product; however, the method also maximizesthe volume and weight of the product, which is often undesirable. Thereis a general need to provide apparatus and methods of providingliquid-based solutions to the market while decreasing the weight of theproduct and space needed to store the product.

The minimization of weight and volume of products is advantageous tomanufactures, retailers and consumers. The manufacturer can reduce thecosts of shipping products by reducing the overall weight and cargovolume of shipments. The manufacturer can also improve the shelf life ofcertain products by eliminating diluting liquids such as water.Retailers can display goods using less shelf space and reduce thephysical workload on employers who stock the shelves. Consumers can moreeasily handle the lighter products and store them more conveniently intheir homes or businesses prior to using the product.

One method of achieving these goals is to sell only the activeingredients. A consumer can purchase the active ingredients and waituntil the product is needed to add the solvent and constitute the finalproduct. This method achieves the goal of reducing weight of the productand storage space of the product. However, this method inconveniencesthe consumer if an adequate package for accommodating the additionalliquid is not provided with the concentrated ingredient. Not only doesan adequate container need to accommodate the proper volume, it mustalso be made of material that is safe when brought into contact with theactive ingredients, and it must be designed for appropriate and safedispensing of the diluted contents. The design of a container canminimize splashing during pouring or make dispensing small amountseasier. In the absence of an appropriate container, the consumer mayhave difficulty in utilizing the concentrated product correctly,efficiently, and in some instances, safely. Accordingly, a need existsfor consumer product packaging that allows manufactures to provideproducts in a concentrated form that minimizes weight and volume,potentially improves product shelf life, and insures the containedproduct is used conveniently, safely and efficiently by the consumer.

SUMMARY OF THE INVENTION

Accordingly, the present invention provides in various embodiments acontainer for storing and dispensing products in their concentrated anddiluted forms. The invention also provides methods for manufacture ofthe container. The container is semi-collapsible, has a hollow body withsupport and collapsible portions, and can be maintained in asubstantially collapsed or a substantially expanded condition. Thecontainer is particularly useful for storing liquid. In its collapsedcondition, the container is especially adapted for storing relativelysmall volumes of concentrated liquid, powders or the like, occupyingminimal space and having a minimal weight. In its expanded condition,the container is especially adapted for receiving and containing largervolumes of liquid which may be added by the consumer of the containedproduct to dilute the concentrated contents. Addition of dilutingliquids and dispensing of the contained product from the container isachieved via a dispenser in the container, and the container is securedfrom leakage via a closure assembly that is coupled to the dispenser.

In various embodiments, the invention provides a semi-collapsiblecontainer capable of moving between a collapsed condition and anexpanded condition. The container includes hollow interior that isdefined at least in part by a side wall and is capable of storing liquidwhen the container is in both its collapsed and expanded conditions, anda dispenser communicating with the hollow interior. The container alsoincludes a base forming a portion of the hollow interior of thecontainer, the base being capable of non-movably supporting thecontainer when the container is filled with liquid in both its collapsedand expanded conditions, a frame forming a portion of the side wall ofthe container, the frame maintaining the dispenser in a fixed positionwith respect to the base regardless if the container is in its collapsedor expanded condition, and at leas one collapsible portion cooperatingwith the base and frame to define the hollow interior of the container.In some embodiments, the container is collapsible in a fashion such thatits front profile is essentially the same regardless of whether thecontainer is in its collapsed or expanded condition.

In accordance with some embodiments, the frame of the container isprovided in the form of an upper end with a dispenser therein, and alower support base. The support portion of the container has an interiorcavity that defines a portion of the volume of the container, and acollapsible portion with a shape that defines a volume that influencesthe total internal volume of the container. The collapsible portion isadapted to be physically movable relative to the support portion betweenan expanded position and a collapsed position. When the collapsibleportion is in the expanded position, the internal volume defined by thecavity of the collapsible portion is available to accommodate liquid orother contents within the interior of the container. According to someembodiments, when the collapsible portion is in the collapsed position,the collapsible portion is inverted into the interior cavity of thesupport portion, and the cavities of the collapsible and supportportions are at least partially nested, thereby reducing the internalvolume of the container available to accommodate liquid or othercontents. In other embodiments, the support portion is not nested withthe collapsible portion when in the collapsed condition. According tosuch embodiments, the collapsible portion is in a non expandedcondition.

In various embodiments, the invention also provides a process for makinga semi-collapsible blow molded article. The process includes the stepsof forming a parison from at least one polymeric resinous material;positioning the parison in a blow mold having an inner shape thatdefines the shape of the article to include at least one support portionand at least one collapsible portion, and introducing air into theparison to force the parison to conform to the inner shape of the mold;and processing the blown article, including the steps, in any order, ofremoving the article from the mold and inverting a collapsible portionof the article into an interior space within a support portion of thearticle. In some embodiments, the process provides a semi-collapsibleblow molded article that is made of at least two different materials,wherein a parison is formed from at least two different polymericresinous materials, at least one of which materials is positioned in theparison in a location that corresponds with the inner shape of the moldthat defines the at least one support portion, and another of whichmaterials is positioned in the parison in a location that correspondswith the inner shape of the mold that defines the at least onecollapsible portion.

Additional features and advantages of the invention will be set forth inpart in the description which follows, and in part will be obvious fromthe description, or may be learned by practice of the invention. Thefeatures and advantages of the invention will be realized and attainedby means of the elements and combinations particularly pointed out inthe appended claims. It is to be understood that both the foregoinggeneral description and the following detailed description are exemplaryand explanatory only and are not restrictive of the invention, asclaimed.

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate several embodiments of theinvention, and together with the description, serve to explain theprinciples of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of one embodiment of a semi-collapsiblecontainer;

FIG. 2 shows another perspective view of the embodiment of thesemi-collapsible container in FIG. 1;

FIG. 3 panel A shows a top view of the semi-collapsible container shownin FIG. 1 in a expanded condition; panel B shows the correspondingbottom view; panel C show the corresponding side view;

FIG. 4 panel A shows a perspective view of the semi-collapsiblecontainer shown in FIG. 1 in a collapsed condition; panel B shows analternate perspective view; panel C show the corresponding side view;and

FIG. 5 panel A shows a cut away side view of the semi-collapsiblecontainer shown in FIG. 1 in an expanded condition; panel B shows anexploded cutaway side view of the detail of an actuation means; panel Cshows a cut away side view of the semi-collapsible container in acollapsed condition alternate ; panel D shows a cut away top view of thesemi-collapsible container in an expanded condition; panel E shows a cutaway top view of the semi-collapsible container in a collapsedcondition.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will now be described with occasional reference tospecific embodiments of the invention. This invention may, however, beembodied in different forms and should not be construed as limited tothe embodiments set forth herein. Rather, these embodiments are providedso that this disclosure will fully convey the scope of the invention tothose skilled in the art.

Except as otherwise specifically defined herein, all terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this invention belongs. The terminology used in thedescription of the invention herein is for describing particularembodiments only, and is not intended to be limiting of the invention.As used in the description of the invention and the appended claims, thesingular forms “a,” “an,” and “the” are intended to include the pluralforms as well, unless the context clearly indicates otherwise.

Unless otherwise indicated, all numbers expressing quantities,properties, and so forth as used in the specification and claims are tobe understood as being modified in all instances by the term “about.”Accordingly, unless otherwise indicated, the numerical properties setforth in the following specification and claims are approximations thatmay vary depending on the desired properties sought to be obtained inembodiments of the present invention. Notwithstanding that the numericalranges and parameters setting forth the broad scope of the invention areapproximations, the numerical values to the extent that such are setforth in the specific examples are reported as precisely as possible.Any numerical values, however, inherently contain certain errorsnecessarily resulting from error found in their respective measurements.

Except as otherwise indicated, the disclosure of all patents, patentapplications (and any patents which issue thereon, as well as anycorresponding published foreign patent applications), and publicationsmentioned throughout this description are, hereby incorporated byreference herein. It is expressly not admitted, however, that any of thedocuments incorporated by reference herein teach or disclose the presentinvention.

The invention is directed, in various embodiments, to a semi-collapsiblecontainer for storing and dispensing products in their concentrated anddiluted forms. The terms “collapsible” and “semi-collapsible” are usedto refer to any space within a container that is effectively reduciblein its size or internal volume by the application of mechanical force todistort its shape, such as by inverting a portion of the container tofold over another portion. The container is capable of expanding from asubstantially collapsed condition to a substantially expanded conditionto accommodate the addition of liquid or other material, and has ahollow body made substantially of an appropriate material, such as athermoplastic material.

According to various embodiments, the semi-collapsible container of theinstant invention includes a hollow interior that is defined at least inpart by a side wall and is capable of storing liquid when the containeris in both its collapsed and expanded conditions, a dispensercommunicating with the hollow interior, a base forming a portion of thehollow interior of the container, the base being capable of non-movablysupporting the container when the container is filled with liquid inboth its collapsed and expanded conditions, a frame forming a portion ofthe side wall of the container, the frame maintaining the dispenser in afixed position with respect to the base regardless if the container isin its collapsed or expanded condition, and a collapsible portioncooperating with the base and frame to define the hollow interior of thecontainer. In some embodiments, the container is collapsible so that itsfront profile is essentially the same regardless of whether thecontainer is in its collapsed or expanded condition. In some particularembodiments, the frame and the base are essentially rigid as compared tothe collapsible portion. As used herein, the terms rigid and essentiallyrigid refer to material properties that influence the stiffness ofportions of the container. For certain embodiments in which the size andvolumes of containers are large, rigidity of portions of the containerwill influence the ability of the container when filled with to resistdeformation caused by the weight of the fluid.

The collapsible portion is adapted to be physically movable relative tothe support portion between an expanded position and a collapsedposition. When the collapsible portion is in the expanded position, theinternal volume defined by the cavity of the collapsible portion isavailable to accommodate liquid or other contents within the interior ofthe container. When the collapsible portion is in the collapsedposition, the collapsible portion is not expanded, and is in someembodiments inverted into the interior cavity of the support portionsuch that the cavities of the collapsible and support portions are atleast partially nested. In other embodiments, the collapsible portion isin a relaxed, flattened, folded or partially inverted state. In thevarious embodiments, the collapsible portion in its collapsed stateeffectively reduces the internal volume of the container available toaccommodate liquid or other contents.

FIG. 1 shows a perspective view of one embodiment of a semi-collapsiblecontainer. Referring to FIG. 1, the container 100 has an upper end 105with a dispenser 110 therein, and a lower support base 115 forsupporting the container in both its collapsed and expanded conditionswhen resting in a generally upright position on a surface. The containerhas a support portion 120 having an interior cavity (125, see FIG. 2)that defines a portion of the total volume of the container. Thecontainer 100 also has at least one collapsible portion 130 with a shapethat defines a cavity (135, see FIG. 2) that influences the totalinternal volume of the container. The collapsible portion 130 is adaptedto move between a substantially expanded position and a substantiallycollapsed position. In the expanded condition, the cavity 135 of thecollapsible portion 130 contributes positively to the total volume ofthe container 100. In the collapsed condition, the cavity 135 of thecollapsible portion 130 contributes negatively to the total volume ofthe container 100. As can be seen in FIG. 3, the collapsible portion 130in this embodiment appears to protrude form the side of the supportportion 120 when in an expanded position.

A container 100 according to the instant invention is formed of one ormore materials that are suited to use in the expanded and collapsedconditions. The particular material is generally selected to becompatible with the intended contents of a container 100. As discussedmore fully below, a container 100 may be manufactured by one of avariety of methods of making containers that are well known in the art.Good results are obtained producing hollow containers using extrusionblow molding techniques with a variety of thermoplastic and elastomericmaterials. Accordingly, in various embodiments according to the instantinvention, a container 100 may be made from one or a combination ofthermoplastic or elastomeric materials, such as: polyesters,Polycarbonate (PC), polypropylene (PP), polyethylene (PE), High DensityPolyethylene (HDPE), Low Density Polyethylene (LDPE), Polyvinyl Chloride(PVC), polyester terphthalate, butadiene-styrene co-polymers,polyamides, ethylene-vinyl-alcohol copolymer, polyethylenenapthaphthalate, thermoplastic and thermosetting resins, polybutyleneterephthalate, polyoxymethylenes, polyphenylene, polyphenylene sulfides,polyphenylene oxides, polymethylmethacrylate, polyethylene-terephthalate(PET), polyvinylidenechloride, polymethylpentene-1, nylon 6, nylon 66,Polyethylene Terephthalate Modified with CHDM (PETG), and mixturesthereof.

Use of thermoplastic or elastomeric materials in making the container100 permits the selection of a broad range of possible materialproperties, including the properties of rigidity, flexibility,elasticity, thermal and chemical resistance, electricalresistance/conductance, mechanical abrasion resistance, catalyticsurface activity, color, transparency/opacity, reflectivity, andtexture. According to some embodiments of the invention, the container100 is made entirely from one material that has uniform properties.According to other embodiments of the invention, the container 100 ismade entirely from one material that has varying properties in variousparts of the container 100. For example, the same thermoplastic orelastomeric material may be selected for the entire container 100 butthe percentages of functional components in each may be varied toprovide varied properties at discrete portions of the container 100.Similarly, in yet other embodiments, two or more different thermoplasticor elastomeric materials may be selected for the container 100, eachforming a discrete portions of the container 100. According to suchembodiments, portions such as the collapsible portion 130 and thesupport portion 120 of the container 100 may vary in properties.

In a particular embodiment, 24. the material of the support portion 120has the property of being more rigid than the material of thecollapsible portion 130, either by varying the functional components ofthe same material or by varying the materials. One such embodiment ofthe invention is a container made up of two portions with each portionmanufactured from a different material. The support portion 120 is madeof a semi-rigid material, of the type that is commonly used forcontainers that are known in the art for containing products such asjuices, or automotive fluids. Typically, such material is a clear oropaque thermoplastic. The semi-rigid material is rigid enough tomaintain a given shape whether there is contents in the container or thecontainer is empty. However, the material is not so rigid that a forceapplied to the material would not cause some deformation. Thecollapsible portion 130 of the container 100 is made of a pliantmaterial. The pliant material generally, adjusts to take the shape ofthe substance inside the container 100. An example of such an embodimentis a container 100 in which the material of the support portioncomprises a blend of LDPE and HDPE, and wherein the material of thecollapsible portion comprises one of LDPE and a blend of LDPE and HDPE.Of course a very large number of combinations of materials can becombined in making a container according to the instant invention, andmethods for making them are well know in the art. In additionalembodiments of the invention, the collapsible portion 130 can be made ofan elastic material that stretches as liquid is added to the container100. The elastic nature of the material could more accurately adjust tothe shape of the contents of the container and potentially furtherminimize the exterior dimensions of the container. In addition, theseembodiments could make it easier for an end user to dispense the productfrom the container 100.

Referring now to FIG. 2, the container 100 is shown in cutawayperspective view in an expanded condition. In the expanded condition,the container 100 has an internal volume that includes the volumesprovided by the interior cavity 125 of the support portion 120 and thecavity 135 of the collapsible portion 130. The container 100 isparticularly useful for storing liquid, and other flowable materials,and in its collapsed condition, the container 100 is especially adaptedfor storing relatively small volumes of products such as concentratedliquids, powders or the like, the products occupying minimal space andhaving a minimal weight relative to their diluted forms. In its expandedcondition, the container 100 is especially adapted for receiving andcontaining larger volumes of liquid or other flowable materials whichmay be added by the consumer of the contained product to dilute theconcentrated product contents. Addition of diluting liquids anddispensing of the contained product from the container is achieved viathe dispenser 110 in the container 100, and the container 100 is securedfrom leakage via a closure assembly (not shown) that is coupled to thedispenser 110.

Referring now to FIG. 3, various perspectives of the container 100 in anexpanded condition are shown. Panel A provides a top view of thecontainer 100 as illustrated in FIG. 1, in an expanded condition, andshows the top segment 131 of the collapsible portion 130 and the upperend 105 of the container 100. Panel B provides a corresponding bottomview of the container 100, and shows the bottom segment 132 of thecollapsible portion 130 and the lower support base 115. And panel Cprovides a side view of the container 100 in an expanded condition, andshows the relative shapes, sizes and configurations of the supportportion 120 and the collapsible portion 130 according to one possibleembodiment of the container 100. Referring to FIG. 3C, the supportportion 120 is formed of a substantially vertical wall, which in someembodiments includes a vertical front wall 121, and in some embodiments,as depicted in FIG. 3, the support portion 120 also includes twosubstantially vertical sidewalls 122 and 122′ (122′ not shown), and aback wall 123. In alternate embodiments of the container 100, thesupport portion 120 may comprise a different configuration ofsubstantially vertical wall or walls around its periphery, as dictatedby the overall shape of the container, as discussed more fully below.

Still referring to FIG. 3C, the collapsible portion 130 also includes asubstantially vertical sidewall 133 which is bounded on the top by thetop segment 131 and on the bottom by the bottom segment 132. Inalternate embodiments of the container 100, the collapsible portion 130may comprise a different configuration of substantially vertical wall orwalls, as dictated by the overall shape of the container, as discussedmore fully below. As can be seen in the various views of FIG. 3, thetotal volume of the container 100 includes the volumes contributed bythe interior cavity 125 of the support portion 120 and the cavity 135 ofthe collapsible portion 130; thus, the cavity 135 of the collapsibleportion 130 makes a positive contribution to the volume of the container100 in the expanded condition.

According to some embodiments, when in the collapsed condition, thecollapsible portion 130 is inverted into the interior cavity 125 of thesupport portion 120, as depicted in the various views provided in FIG.4. Referring now to FIG. 4, panel A provides a front perspective view ofthe container 100, panel B provides a corresponding rear perspectiveview, and panel C provides a side view. As can be seen, the cavity 135of the collapsible portion 130 is nested within the interior cavity 125of the support portion 120. According to the depicted embodiment of thecontainer 100, when the cavities of the support 120 and collapsible 130portions are nested, the substantially vertical walls 121, 122, and 122′of the support portion 120 and the substantially vertical wall 133 ofthe collapsible portion 130 are moved adjacent to one another, and arein some embodiments at least partially in contact. Likewise, in thecollapsed condition, the bottom segment 132 of the collapsible portion130 and the lower support base 115 are moved adjacent to one another,and are in some embodiments at least partially in contact. Of course itwill be appreciated that in other embodiments, the position of thecollapsible portion 130 relative to that of the support portion 120 mayvary; for instance, the collapsible portion 130 may be in a flattened orrelaxed state, it may be folded, creased or otherwise positioned withoutbeing inverted or nested with the support portion 120.

Of course it will be understood, as more fully discussed below, that theoverall shape of each of the nested cavities 125 and 135 of the support120 and collapsible 130 portions will influence the extent to which thesegments of the container 100 are adjacent to or in contact when thecontainer 100 is in the collapsed condition. And it will be appreciatedby one of ordinary skill that when the cavities 125 and 135 of thesupport 120 and collapsible 130 portions are nested, the cavity 135 ofthe collapsible portion 130 contributes negatively to the total volumeof the container 100 by effectively reducing the total volume of thecontainer by the volume of the cavity 135 of the collapsible portion 130and by at least a portion of the volume of the internal cavity 125 ofthe support portion 120. The extent of the volume reduction of theinternal cavity 125 of the support portion 120 is influenced by theoverall dimensions and shape of the collapsible portion 120.

In various embodiments, the container 100 according to the invention iscapable of being manipulated between a collapsed and an expandedcondition. The collapsible portion 130 is moved between an expandedposition and a collapsed position by actuation of a means located at theinterface 200 between the collapsible portion 130 and the supportportion 120. As noted above in relation to FIG. 4, when in the collapsedcondition, the collapsible portion 130 is inverted into the interiorcavity 125 of the support portion 120. Referring again to FIG. 4, panelB provides a rear perspective view of the container 100 illustrated inFIG. 1, in a collapsed condition, and shows the interface 200 betweenthe support portion 120 and the collapsible portion 130 (which isinverted, and nested within the cavity 125 of the support portion 120).The actuation means 250 is positioned substantially at the interface200, and is adapted to permit the movement of the collapsible portion130 between the expanded and the collapsed positions.

Referring still to FIG. 4B, as shown in the depicted embodiment, theactuation means 250 is integral with the container 100 and is adapted tomaintain a watertight seal at the interface 200 between the supportportion 120 and the collapsible portion 130. Generally, the actuationmeans 250 is made of a material that is the same as or similar to thematerial(s) used to make one or both of the support portion 120 and thecollapsible portion 130. As shown in the various figures providedherein, the actuation means 250 is formed from the same material(s) usedto make one or both of the support portion 120 and the collapsibleportion 130. In other embodiments not illustrated herein, the actuationmeans 250 may be formed from material that is different from thematerial(s) used to make one or both of the support portion 120 and thecollapsible portion 130. In yet other embodiments not illustratedherein, the actuation means 250 may be formed separately from and notintegrated with the either or both the support portion 120 and thecollapsible portion 130. According to such embodiments, the actuationmeans 250 may be in the than of a gasket, grommet, or other band or sealthat is inserted at the interface 200 after manufacture of the supportand collapsible portions 120 and 130. And in yet other embodiments, thematerial forming the actuation means 250 is different from those of thesupport and collapsible portions 120 and 130 and is inserted or attachedto the container 100 as a final assembly step.

In some embodiments, the actuation means 250 is a hinge or hinge likestructure. Examples of hinge shapes and configurations suitable for theactuation means 250 according to the instant invention include shapesthat have one, two, three, four or more bends. Examples of single bendhinges include hinges that are generally “C,” “U,” or “V” shaped.Examples of double bend hinges include hinges that are generally “S,” or“Z” shaped. Yet other hinges with additional bends may be used accordingto the invention. According to embodiments wherein the actuation means250 is a hinge, a variety of hinge shapes and types are known in theart.

According to embodiments of the invention in which the actuation means250 is a hinge, a variety of hinge shapes and types are known in the artand may be selected therefrom. An example of a type of hinge type thatis useful according to the instant invention is a living hinge. As usedherein, the term “living hinge” means a hinge with no moving parts thatis is characterized by its excellent fatigue resistance. Living hingesare typically formed of thin segments of plastic that connect two partsof an article to keep them together and allow the article to be openedand closed. Living hinges are desirable because they are generally ableto flex up to a million or more cycles without failure. The materialsused to make a living hinge include very flexible plastics, such aspolypropylene and polyethylene, and other thermoplastic materials asdescribed herein.

The actuation means 250 shown in FIG. 5 (and the other figures shownherein) is a Z shaped living hinge. Panel A provides a cutaway side viewof a container 100 in the expanded condition. The figure features adotted circle in the lower left hand portion corner highlighting thedetail of the actuation means 250. Panel B provides an exploded cut awayperspective view of the detailed area from Panel A, showing the Z-shapedliving hinge actuation means 250 of the illustrated embodiment. As canbe seen in FIG. 5B, the illustrated portion of the actuation means 250is shown adjacent to the lower support base 115 of the container (bottomright of the figure) and the collapsible portion 130 (upper left of thefigure). Still referring to FIG. 5B, the depicted hinge has three legs251, 252, and 253, arranged in series, with leg 251 adjacent andattached to the support portion 120. Leg 252 is positioned between leg251 and 253, and leg 253 is in turn adjacent to the collapsible portion130 of the container 100. The illustrated actuation means 250 allows forthe collapsible portion 130 to be inverted from the expanded position byfolding along the hinge. FIG. 5C provides a cutaway side view of acontainer 100 in the collapsed condition, and FIGS. 5D and 5E each showa cutaway plan view of the container 100 in the expanded and collapsedconditions, respectively. As can be seen from each of these views, thelegs 251 and 252 of the actuation means 250 intersect to form a hingeedge 255 that extends from the surface of the container 100 around theinterface 200 between the support and collapsible portions. In alternateembodiments in which a hinge having fewer than three legs is used, thehinge edge may not be present. In yet other embodiments in whichadditional hinge legs are used or different hinge configurations areused, a more pronounced or differently shaped hinge edge may be present.The choice of hinge, or of living hinge design, is influenced by theproperties of material used, including pliability, rigidity, elasticityand the like. Hinge selection is within the skill of those of ordinaryskill in the art.

According to the invention, the container 100 has a shape that is suitedto containing liquid and other flowable materials. As such, the overallsize, shape and configuration of the container 100 may vary as suited tothe intended contents and uses by the consumer of the contained goods.Likewise, the relative proportions of the upper end 105, lower supportbase 115, support portion 120 and collapsible portion 130 may vary asneeded to accommodate contents of varying density, viscosity, etc. Forparticularly small containers, certain shapes may be favored, such asmore streamlined cylindrical shapes. For particularly large containersthat will hold larger volumes, and hence be heavier upon addition ofdiluent, less streamlined and more hefty and ergonomically designedshapes may be favored. One of ordinary skill will appreciate that theoverall shape and arrangement of features such as dispending openings,handles, and other features may be selected as appropriate to the use ofthe container.

In some embodiments, the container 100 according to the invention has anoverall substantially cylindrical shape. In other embodiments, thecontainer 100 has an overall substantially polyhedral shape. In yetother embodiments, portions of the container 100 has a shape that is acombination of cylindrical and polyhedral shapes. For example, in someembodiments, both the support portion 120 and the collapsible portion130 have a substantially cylindrical shape, wherein the support portion120 has a substantially arcuate vertical wall, and wherein thecollapsible portion 130 has a substantially cylindrical vertical face.In other embodiments, both the support portion 120 and the collapsibleportion 130 have a substantially polyhedral shape, wherein the supportportion 120 has a substantially flat vertical wall bounded by sides thatare either substantially flat or rounded, and wherein the collapsibleportion 130 has a substantially cylindrical vertical face asubstantially flat vertical wall likewise bounded by sides that areeither substantially flat or rounded. And in yet other embodiments, oneof the support and collapsible portions 120 and 130, respectively, has asubstantially polyhedral shape while the other has a substantiallycylindrical shape.

In various embodiments, the collapsible portion 130 according to theinvention has top and bottom segments 131 and 132 of varying shapes. Insome embodiments, the top segment 131 has a domed shape, and the bottomsegment 132 is flattened, as shown in the embodiment of the container100 depicted in the figures, for example, FIG. 2. In yet otherembodiments that are not shown, the top segment 131 has a squared orpeaked shape, and the bottom segment 132 is rounded. In still otherembodiments, the segments of the collapsible portion 130 may be baffledor folded, and may be ribbed, rippled or pleated. One of ordinary skillwill appreciate that a variety of combinations of shapes and folds maybe used for the top and bottom segments 131 and 132 of the collapsibleportion 130 of the container 100 according to the instant invention.

Likewise, the vertical wall 121 of the support portion 120 may be formedin the shape of a cylinder, as mentioned above, wherein the verticalwall 121 is substantially continuous and arcuate in shape. In otherembodiments, the vertical wall 121 of the support portion 120 may begenerally polyhedral in shape, and formed of a substantially flat frontwall 121 bounded by substantially flat or curved side walls 122 and 122′and have a back wall 123 opposing the flat front wall 121, the back wall123 being substantially flat or curved.

The interface 200 between the support portion 120 and the collapsibleportion 130 may have a variety of shapes and configurations. Accordingto the illustrated embodiment, as shown in representative FIG. 4B, theinterface 200 is generally arch shaped on the top and squared on thebottom, the shape being formed by the generally domed shape of the topsegment 131 and the generally flatted shape of the bottom segment 133 ofthe collapsible portion 130. Of course it will be appreciated thatvariations in the shape of the segments of the collapsible portion 130will influence the shape of the interface 200, and that generally anyshape will be suitable to accommodate the function of actuating movementof the collapsible portion 130 between the expanded and collapsedpositions. More generally, containers, such as bottles, having a varietyof shapes are well known in the art, and the design of shaped featuresare known to those of ordinary skill.

Referring again to FIG. 1, the container 100 in accordance with theinstant invention has an internal volume that includes the combinedvolumes of the cavities of the support and collapsible portions.According to the embodiment depicted in the figures, the support portion120 forms at least one half of the surface area of the container 100 andabout one half or more of the volume of the container 100; thecollapsible portion 130 forms not more than one half of the surface areaof the container 100, and about one half or less of its volume. Inalternate embodiments that are not shown, the relative contributions tothe container 100 size and volume by each of the collapsible and supportportions 130 and 120, respectively, may vary. For example, in someembodiments, the support portion 130 may contribute as little as 10, 15,20, 25, 30, 35, 40 or 45 percent of the container or its volume. And inother embodiments, the support portion 130 may contribute as much as 55,60, 65, 70, 75, 80, 85, 90 or 95 percent of the container or its volume.By varying the sizes, shapes, and relative thickness and rigidity of thecollapsible and support portions 130 and 120 of the container 100, awide variety of container configurations are possible in accordance withthe invention.

Referring still to FIG. 1, in its various embodiments, the lower supportbase 115 and the upper end 105 are on the support portion 120 of thecontainer 100. In various embodiments, the lower support base 115 iseither substantially rectangular, square, circular, crescent, ordisc-like in shape. The illustrated embodiment has a lower support base115 that is substantially rectangular, as shown in representative FIG.3B. The support base 115 is in contact with the support portion 120 atleast at the front of its vertical wall 121. In the depicted embodimentshown in FIG. 1, the support base 115 is in contact around its perimeterwith the support portion 120 at the front wall 121, side walls 122 and122′ and back wall 123. Other configurations are possible. In someembodiments, the support base 115 is in contact with the support portion120 via an edge 140, which is identified in FIG. 3C. The edge 140 may bebeveled as shown in the illustrated embodiment, it may be rounded, or itmay have another shape, curvature or texture, including one or morelevels formed, for example, by one or more beads or crowns. In otherembodiments, the support base is in contact with the support portion atsubstantially a 90 degree angle, in the absence of an edge or bevel.

Referring again to FIG. 1, the upper end 105 of the container 100includes a dispenser 110. And in the depicted embodiment, the container100 also includes a handle 112, although it will be appreciated that inother embodiments, the feature of a handle is not included. In variousembodiments, the upper end 105 has a shape that is conducive toefficient dispensing of the contents of the container 100. In someembodiments that are not shown, the upper end 105 has a substantiallydomed shape, with the dispenser positioned at the top of the dome. Inother embodiments (not shown), the upper end 105 has a substantiallyinverted truncated conical shape, with the dispenser positioned at theapex of the cone. And in still other un-shown embodiments, the upper end105 has a substantially cylindrically shaped neck that is taperedrelative to the body of the container, with the dispenser positioned atthe top of the neck. It will be appreciate that a wide range of shapesand configurations of bottle tops and dispensers are known in the artand can be adapted for use with the containers of the instant invention.

As mentioned previously, in some embodiments the container 100 has ahandle. A handle provides a variety of functions that influenceefficient use of the container 100. For particularly large-volumecontainers, a handle is useful for providing structural support to aidin stacking and weight distribution when the container is filled. Ahandle is also useful for ergonomic purposes, particularly when thecontents are heavy and difficult to dispense merely by grasping the bodyor neck of the container. Likewise, a handle reduces the need forstructural rigidity in the body of the container, which is moreimportant if the container is to be grasped by the body for dispensing.Finally, a handle, when hollow and positioned at or near the top of thecontainer, can aid in venting during dispensing, and thereby improveflow when the contents are dispensed. In embodiments of the container100 that comprise a handle, the handle 112 may be offset from a centralaxis of the container, being positioned on the upper end 105 andadjacent to the dispenser 110. In other embodiments, the handle 112 maybe positioned on the upper end 105 and inline with the dispenser 110.And in yet other embodiments, the handle 112 may be positioned at somedistant location relative to the upper end 105, such as along thevertical wall of the support section 120. And in still otherembodiments, the container 100 may have more than one handle 112, eachhandle being positioned at one or more of the various locations on thecontainer 100, arranged in either a symmetrical or nonsymmetricalrelative orientation.

In various embodiments, the container may comprise a closure means 150,as identified in FIG. 2. A variety of closure means for sealingcontainers and other bottles are well known in the art, and include, butare not limited to openings that have ridges, threads and otherstructural features for receiving and retaining a closure device, suchas a cap or lid. The container 100 may likewise comprise a closureassembly, such as a cap or lid. The closure assembly (not shown) may bein one or more pieces, and may have features that indicate rupture of aseal, protect against opening by children, or protect against leakage orpassage of liquid or vapor into or out of the container 100. Accordingto such various embodiments, the closure assembly may be removablycoupled to the container 100, or it may be a single use closure. In someembodiments of the invention, a device, such as a pull ring, may beattached to the outside of the collapsible portion 130 to enable theuser to manually pull the collapsible portion 130 away from the body ofthe container 100 when the container is in a collapsed condition.

In all embodiments described above it is understood that the containermay come in a variety of sizes and shapes. The figures presented showtraditional one gallon and half-gallon bottle container; however, thisdoes not preclude the container from taking on other sizes and shapes,such as all sizes of drums, barrels, boxes, cans, and the like.

Methods of Making Containers

The invention also provides methods for making semi-collapsiblecontainers. Generally, there are many methods for making containers. Anexemplary method is extrusion blow molding. The extrusion blow moldingprocess involves multiple steps, including conventional extrusion of aparison or tube, using a die. The parison is commonly extruded downwardbetween one or more sections (usually two halves) of an open blow moldthat has an internal shape that forms the shape of the article to bemolded. The parison is quite hot, while the internal surface of the moldis relatively cold. When the parison reaches the proper length, the moldis closed, and the parison is caught and held in place at either end. Arod-like blow pin is inserted into the one end of the hot parison toinflate the parison inside the mold cavity, and in some cases, to form athread or other structure at what will be the dispenser of thecontainer. After the blown article cools, the mold is opened and thearticle is removed or ejected. The article is then processed to trim anyexcess plastic from the areas that were pinched at the neck and bottomand along the seams of the mold. The procedures for forming bottles andother containers are well known. For example, see Modern PlasticsEncyclopedia, Vol. 54, No. 10A, 1977-1978, McGraw-Hill Publishing Co.(e.g., section on “Blow Molding” at page 230, et seq.; also see sectionon “Injection Blow Molding” at page 232 et seq.).

According to the invention, modifications to the blow molding processprovide for making a semi-collapsible blow molded article. The processincludes the steps of forming a parison from at least one polymericresinous material; positioning the parison in a blow mold having aninner shape that defines the shape of the article to include at leastone support portion and at least one collapsible portion, andintroducing air into the parison to force the parison to conform to theinner shape of the mold; and finally processing the blown article,including the steps, in any order, of removing the article from the moldand inverting a collapsible portion of the article into an interiorspace within a support portion of the article.

The step of collapsing the container may be achieved by introducing anadditional mandrel bearing a punch or other tool that conforms to theshape of the support portion and is adapted for removable insertion toeffectively collapse the container without causing damage to itsstructure. Alternatively, the collapsing step may be performed manually,such as with a hand, or a specially adapted tool. In some embodiments,the parison is formed from at least two different polymeric resinousmaterials, at least one of which materials is positioned in the parisonin a location that corresponds with the inner shape of the mold thatdefines the at least one support portion, and another of which materialsis positioned in the parison in a location that corresponds with theinner shape of the mold that defines the at least one collapsibleportion. According to such embodiments, containers having portions madeof different materials can be made, such as containers in which thecollapsible portion and the support portions vary in their flexibility,rigidity, elasticity, or opacity or color.

Use of Containers

Containers of the instant invention are intended for use by consumers ofa variety of products of an industrial, household, or other nature, thatcan be provided in a concentrated form (either powder, liquid, or otherform) for later suspension, reconstitution or dilution. The cavity ofthe support portion that is available in the collapsed condition of thecontainers provides sufficient space to contain active ingredients or aconcentrated liquid solution. Accordingly, after manufacture of acontainer, it is ready for placement of an appropriate amount of activeingredient or concentrated solution into the container. Thereafter, thecontainer is sealed. An advantage of the container design according tothe invention is that the addition of product to the collapsed containerresults in some degree of distortion of the container and an attendantincrease in the internal volume. Thus, if a seal is applied to thecontainer immediately upon addition of the product, a vacuum will formdue to the increase in internal volume caused by the force of the addedproduct. In some instances, manufactures and packagers may be spared therequirement of evacuation if the product contents are otherwise stable.

After the product in the container is purchased, the user adds water oranother appropriate solvent to the container to arrive at the correctconcentration of product. As the liquid is added, the collapsibleportion expands and moves out of the interior of the support portion andassumes its shape as it is filled with the added solvent. In general, insome embodiments of the invention, the collapsible material does notnecessarily rely on significant elasticity to accommodate increases incontainer volume. The material itself does not substantially stretch orshrink when liquid is added or removed, only the shape of thecollapsible material changes to increase or decrease the volume capacityof the container. When the container is in either the expanded or thecollapsed condition, the bottom of the support portion supports andmaintains the container in an upright position when set onto an levelsurface.

The flexibility of the internal volume and outside dimensions of thecontainer allow for efficiency gains in the packing and shipping ofcontainers by conserving overall space and volume when containers aresituated next to one another. Containers can be designed in a mannerwhere the shape of the support portion fits into the shape of thenon-expanded pliable portion. Generally, the shape of the supportportion is compatible with the shape of the collapsible portion. Thisallows the support portion of a container to be seated adjacent to thecollapsible portion of a container situated next to it, however, theshelf space needed to accommodate the containers is smaller. When viewedfrom the front by a shopper, the containers on a shelf appear verysimilar to traditional containers, and include labels, markings andother product-related indicia typically associated with moretraditionally packaged products.

Manufactures, retailers and customers alike further benefit from thespace saving design of the container, since the void provided in theoutwardly facing concavities of the body of the container provide aspace that can be used for enclosing tools for use with the container,such as pumps, measuring cups or spoons, dispensing containers,additional caps and the like. The space can also be used for enclosinginstructions. And the space can be used for enclosing promotional items,such as coupons, juice glasses, children's toys, and other items thatappeal to consumers.

The embodiments described above are examples only, and are not intendedto limit the scope of the claims set forth below. Variations to theinventions described herein, including alternate embodiments notspecifically described, are quiet possible and are encompassed by theclaims as understood by one of ordinary skill in the art. Indeed, theclaimed inventions have their broad and ordinary meaning as set forthbelow in the claims.

1. A container comprising: a support portion; and a collapsible portionconnected to the support portion such that an internal volume is definedbetween the support portion and the collapsible portion; wherein thecollapsible portion is moveable between a expanded condition and acollapsed condition; wherein when said collapsible portion is in theexpanded condition said internal volume comprises a volume of aninternal cavity of the support portion and a volume of an internalcavity of the collapsible portion; wherein when said collapsible portionis in said collapsed condition the collapsible portion is inverted intothe internal cavity of the support portion; wherein the collapsibleportion is configured such that adding water to the collapsiblecontainer when the collapsible portion is in the collapsed conditioncauses the collapsible portion to move to the expanded position.
 2. Thecontainer of claim 1 further comprising a concentrated product disposedin the internal volume of the collapsible container when the collapsibleportion is in said collapsed condition.
 3. The container of claim 2further comprising a seal that is applied to the collapsible containerimmediately upon addition of said concentrated product to said internalvolume of the collapsible container such that a vacuum forms in saidcollapsible container due to an increase in internal volume caused bythe force of adding said concentrated product.
 4. The container of claim1 wherein both the support portion and the collapsible portion are madefrom the same material.
 5. The contained product of claim 4 wherein saidmaterial is a blend of Low Density Polyethylene and High DensityPolyethylene.
 6. A container comprising: a support portion; acollapsible portion connected to the support portion such that aninternal volume is defined between the support portion and thecollapsible portion; a hinge portion that connects the collapsibleportion to the support portion; wherein the support portion, thecollapsible portion, and the hinge portion are integrally formed from auniform material; wherein the collapsible portion is moveable between anexpanded condition and a collapsed condition; wherein when saidcollapsible portion is in the expanded condition said internal volumecomprises a volume of an internal cavity of the support portion and avolume of an internal cavity of the collapsible portion; wherein whensaid collapsible portion is in said collapsed condition the collapsibleportion is inverted into the internal cavity of the support portion;wherein the collapsible portion and said hinge portion are configuredsuch that adding water to the collapsible container when the collapsibleportion is in the collapsed condition causes the collapsible portion tomove to the expanded position.
 7. The container of claim 6 wherein thehinge portion extends around an entire interface between the supportportion and the collapsible portion, wherein the hinge portion comprisesa first leg that is attached to the support portion, a second leg thatis attached to the collapsible portion, and a third leg that connectsthe first leg to the second leg.
 8. The container of claim 6 furthercomprising a concentrated product disposed in the internal volume of thecollapsible container when the collapsible portion is in said collapsedcondition.
 9. The container of claim 8 further comprising a seal that isapplied to the collapsible container immediately upon addition of saidconcentrated product to said internal volume of the collapsiblecontainer such that a vacuum forms in said collapsible container due toan increase in internal volume caused by the force of adding saidconcentrated product.
 10. The container of claim 6 said uniform materialis a blend of Low Density Polyethylene and High Density Polyethylene.11. A method of containing a product comprising: providing a collapsiblecontainer comprising: a support portion; and a collapsible portionconnected to the support portion such that an internal volume is definedbetween the support portion and the collapsible portion; wherein thecollapsible portion is moveable between an expanded condition and acollapsed condition; wherein when said collapsible portion is in saidcollapsed condition the collapsible portion is inverted into theinternal cavity to form an outwardly facing concavity; adding aconcentrated product to an internal volume of the collapsible containerwhen the collapsible portion is in said collapsed condition; addingwater to the collapsible container when the collapsible portion is inthe collapsed condition, wherein said adding said water causes thecollapsible portion to move to the expanded position.
 12. The method ofclaim 11 further comprising applying a seal to the collapsible containerimmediately upon addition of said concentrated product to said internalvolume of the collapsible container such that a vacuum forms in saidcollapsible container due to an increase in internal volume caused bythe force of adding said concentrated product.
 13. The method of claim11 wherein both the support portion and the collapsible portion are madefrom the same material.
 14. The method of claim 13 wherein said onematerial is a blend of Low Density Polyethylene and High DensityPolyethylene.
 15. The method of claim 11 wherein both the supportportion and the collapsible portion are made from one material havinguniform properties.
 16. The method of claim 15 wherein said one materialis a blend of Low Density Polyethylene and High Density Polyethylene.